Molding apparatus



F b- 12, 1946. c. v. SMITH MOLDING APPARATUS Filed July 5, 1943 2 Sheets-Sheet l INVENTOR CHARLES V SMITH amsm ATTORNEYS of the finished lens or plano.

of the plastic to the glass has been sufflcient to causes internal movement'of the Patented Feb. 12 1946 UNITED STATE 2,394,941 MOLDING APPARATUS 1 Charles V. Smith, Worcester, Mass., The Univis Lens Company, Dayton,

poration of Ohio assignor to Ohio, a cor- Application July 3, 1943, Serial No. 493,390-

- 4 Claims.

This invention relates to a method and apparatus for producing articles of optical perfection from synthetic resinous materials.

There have been previous attempts to produce true optical articles by forming blanks of resinous material into the shape of a lens or a plano. However, many of these former attempts have not been wholly satisfactory, since the surface finish of the lens or piano was not as perfect as it should be. Further, the lenses have contained strain, which can be referred to as optical strain, of. sufficient value that the optical properties of the lens or piano were affected. In the previous attempts the lens or plane was formed in a single operation. This single operation generally prod'uced optical strain of sufficient value toimpair the optical properties of the lens or plano, specifically resulting in bi-refringence. Also, it has not been entirely impractical to form a lens in a single mold since the movement of the surface of the blank of resinous material has been affected deleteriously.

7 of a lens or an optical plano, have been made from various materials, each of which have had certain disadvantages. To form a lens or plane in metal dies solely, it has been very difficult to produce a surface finish of sufflcient optical perfection. The surface of the lens or piano formed in a single metal die has resulted ina surface which is pitted or wavy, since it has not been possible to produce a perfect surface upon the metal. While the imperfections are slightand imperceptible to the eye, yet they are of sufficient value to destroy the optical perfection of the surface of the lens or piano.

Glass dies have been tried for completely forming a lens or plano in a single operation. -Many of the synthetic resins which have favorable optical characteristics have a considerable amnity for glass. Hence, when blanks of resinous material have been formed in glass dies to form a lens or piano, the resinous material has tended to adhere to the surface of the glass die, this retards the movement of the material within the die and results in imperfections upon the surface Also, the adhesion retard the surface movement of the plastic thereover to an extent that the internal mass of the blank of resinous material has been moved without noticeable surface movement. This action blank to an ex-' of acrylic or methacrylic acids.

tent that produces strain of suflicient value, to destroy theoptical properties of the material.

The materials which have previously been used, and which have particular aflinity for glass, have been those organic resins which are produced by the polymerization of the monomeric derivatives The substances used are commonly known to the trade as Plexiglas, Lucite, Crystalite, and others.

It is thus an object of my invention to provide a method for producing an optical article such as a lens or plano, having a surface which is of high optical perfection. Q,

- It is another object of my invention to provide a method for producing an optical article having high surface optical perfection by forming the article in a succession offorming dies.

It is another object of my invention to relieve stress developed by forming a blank of resinous material by successive forming and heating operations.

It is another object of my invention to form an optical article, such as a lens or plano, by forming the article in a succession of forming dies, each of which is more accurate as to optical curvature than the previous die.

It is still another object of my invention toprovide a method for producing a lens or piano by a succession of forming operationsthe earlier in metal dies and the of which are carried out last operation of which is carried out in a glass surfaceddie. Y

It is another object of the invention to produce a lens or piano having surfaces of substantially true optical curvature within metal dies and to produce an optical surface piano within glassdies.

It is still a further object of this invention to produce a lens or piano by a succession of forming operations, each of which is complete with a heating, forming and cooling operatiomeach of the operations bringing the lens or piano to a greater degree of accuracy of surface of optical curvature.

Another object of the invention is to provide a succession of forming dies for producing a lens or piano in a manner to produce equal formin pressure upon all the die during forming operation.

Another object of the invention is to provide a companion set of forming dies for successive forming operations upon a blank of resinous mafinish for the lens or upon each of the companion dies simultaneously during the various successive forming operations.

. through the supply pipe 24. The fluid circulating Another object of the invention is to provide an apparatus for applying equal pressure upon a plurality of companion forming dies.

Another object of the invention is to arrange a companion set of three forming dies at the apexes of an equilateral triangle, whereby pressure applied upon the dies will be distributed equally between the same.

A still further object of the invention is to provide a companion set of forming dies having means forindividual adjustment to arrange for even distribution .01 pressure therebetween.

A still further object of the invention is to produce a lens or piano from a blank of synthetic resin in a succession of complete forming operations consisting of heating, forming and cooling, each successiveforming operation bringing the lens or piano to a greater degree of accuracy at each successive heating, relieving to some extent the stress developed by the previous forming operation.

Further objects and advantages will be apparent from the description and the'drawings.

In the drawings:

i ure 1 is a diagrammatical representation of a system for producing a lens or piano according to the teachings of this invention,

Figure 2 is a perspective view, partially in crosssection, of a cast metal die,

Figure 3 is a perspective view, partially in cross-section, of a metal die having a, highly finished surface of optical curvature,

Figure 4 is a perspective view, partially in crosssection, of a glass die for producing the finished surface of optical curvature,

Figure 5 is a cross-sectional view of a modification of the die of Figure 4 1 Figure 6 is a cross-sectional view of a further modification of the die of Figure 4,

Figure 'I is a cross-sectional view of a third modification of the die of Figure 4.

resinous material which i altered in shape to.

through the supply pipe 24 is conducted to the die carrying members 20 and 2| by means of the conduits 25 and the branch conduits 23 and 21.

The fluid, circulates through the die carryingmembers 20 and 2|, and discharges through the return conduit 28, which communicates with a return conduit 28. The supply line 24 may be alternately supplied with heating and cooling fluid according to the cycle of operation of the pressing molds supplied thereby. The entire group of companion molds may operate within a single cycle of operation wherein all of the molds heat, form and cool simultaneously, or a suitable valve arrangement and supply pipe system can be arranged to permit each of the presses to operate as a complete individual unit. In either case, the cycle of operation of the press wil1.be the same, and will effect the sequential or successive forming operations upon a blank of form a'iens or piano.

The diaphragm motors 23 are connected to a source of pressure supply, such as the conduit 33. The branch lines 3| for each of the air motors 23, are provided with a valve 32 which may be either manually or automatically controlled:

The dies l5 consist of a pair of metal castings I I51: and |5b in which a surface of optical curvature 35 is provided in the die |5a. The surface of optical curvature 35 is cut to the desired curvature for the desired side of the curvature of a lens or piano. The die half lib cooperating with the die half |5a is provided with the cooperating surface of optical curvature for producing a lens or piano. The optical curvature given the surface 35 and thecooperating surface vof the die I 5b is substantially the curvature which will produce a lens or piano into a substantially finished formed optical article. The surface of the cast metal dies, however, is not sufliciently perfect to Figure 8 is a cross-sectional *view taken along the lines-8 of Figure 9, showing the grouping of a plurality of forming dies,

Figure 9 is a cross-sectional view taken along the line 8-9 of igure 8, and

-' Figure 10 is an eievational perspective view of a modified form of die arrangement wherein the individual dies are adjustable in height.

In this invention, I provide a plurality of molds or dies which form a companion set for forming a blank of resinous materialinto a lens or piano by a succession of forming operations. In general, I provide a mold or die It, provided with a face having an optical curvature. This die illprovides a, rough pre-forming of the-blank of resinous material to a curvature somewhat approaching the curvature of the surface of a lens or piano. The blank of resinous material which has been preformed in the die Hi, can subse quently bemore accurately formed within the cast dies IS, the dies l6 having a highly finished surface of optical curvature, and the finishing glass'dies l1.

The die ||l, as well as the dies l5, l8 and H, are positioned within suitable presses which consist of a lower die carrying member 20 and an upper die carrying member 2|. The die carrying member 20 is positioned upon the end of a reciprocating plunger 22. which in turn is secured to a diaphragm motor 23.

The die carrying members 20 and 2| are provided with suitable passages therein for the cir-, culation of a heating or cooling fluid therethrough. The heating or cooling fluid is circulated provide a surface finish upon the blank of resinous material which has been formed therein. Also, since the cast metal dies I5 provide the first step of accurate formation, the exactness of the lens or piano need not be true within these dies, the purpose of the dies being to provide the greatest physical alteration required in the formation of the lens or piano, and move the greatest mass of material.

Subsequent forming operations will provide the desired degree of mathematical accuracy to the surface of optical curvature of the lens or piano,

and provide a surface finish for the same. The dies it which consist of a pair of metal dies I64:

and |6b are provided with a surface. of optical curvature 36. The surface of optical curvature 36 is a highly finished metal surface, and may be provided by plating a very dense and hard metal, such as chromium, upon the surface which forms the surface of optical curvature. The chromium surface of the accurately cut 'surface of optical curvature 36 maybe subsequently polished to provide a high degree of accuracy and smoothness. The dies iii, if desired, can be made from hard steel and the surface of optical curvature being accurately ground thereon and subsequently polished.

The blank of resinous material which has been formed in the dies I5 is placed within the dies i6 for a further forming operation. The polished face of the surface of optical curvature of the dies l6 will bring the blank of resinous material more nearly to the degree of mathematical accuracy desired for the surface of the lens or pol h, Marsh -w v poptic'al perfection is not obtainable in these dies.

through the blank of resinous :material. ..l. blank may be altered in physical shapei andf co ingmembers 2 and 2| for reducing thetem no; the men 'rfection upon the surface of the blank'of ed surface the surface finish of the desired 'The dies'il which consist of. the die members Ila and I'll) are constructed of glass. The die member llq' having a surface of optical curvature 31 thereon. The glass dies I! can be ground to the exacting degree'of mathematical accuracy required for the production of complicated lenses, and can be polished to the extremely high degree required to produce a, surface finish upon the blank of resinous material sufilcient to give the blank a surface flnishcomparable with the glass.

vmaterial. However, since even the highly of the dies I8 is porous and {P H a degree of nnish o f-the 'dies will impart a higher degree pr otoptibe permitted to reduce temperature'at w I to return to its normal unformed condition.

deaired,the diecarrying is then placed through subsequent forming op- After the .blank of resinous material has been prefinished in the dies I6, it is pressed within the 'dies' l1 and formed therein to the exacting requirements of ahighly accurate lens.

While thedies ll can made from glass blocks, yet it is also possible that the dies ll can be made from metal blocks which are either surfaced with a I V positioned therein. Such-modified arrangements glassface or have glass inserts erations for producing an accurate surface of optical curvature and for producing a finishing surface upon the blank of high optical perfection.

The pre-formed blank of resinous material removed from the die It is placed within the dies it. Since the formed blank contains internal stress produced by the previous forming operation, the dies I! are closed upon the formed blank and a pressure applied thereupon by means of the diaphragm motor 23a. Since the formed blank is placed within the dies IS in a cold condition, the order of pressure which can be applied are shown by Figures 5to 7 inclusive, wherein the die ll of Figure 5 consists .of afmetal base member 40 with a glass face ll positioned therein. The modification :of Figure 6' consists of a metal base 42 having'a glasslin'sert-ll. which is loosely positioned within'a recess in the base 42. The,

glass insert 43 1s provided. with thedesired sur-. face'of optical curvature '44: The modification of Figure .7 is substantially'thesameraszzthat'of Figure 6 xcept that the metalbase 'fl'ais' ametal which has the same coeflici'ent Y of expansion glass, so that .theinsert 43 can besecur'ed'pe H manentlyto the base l2a.' I To, produce a lens or optical piano from a blank of resinous material by the teachings offthe method of this invention, a blank of material'of the proper size and thickness is positioned upon the die half l0a.' Pressure is applied to the air motor 23 by operation of the valve 32, whereby the plunger gagement with the die half lllb. Heat is applied to "the die carrying members and 2| whereby the temperature of the blank of resinous material upon the die I0 is elevated toua temperature determined by the temperature ofthefluid cir' culating through the die carrying members 20 and 2|. The rate of pressure application applied upon the resinous blank is controlled in accordance with a predetermined rate. This rateis'determined by the temperature at which the blank is to be formed, and is determined to be the rate which will not produce deleteriousoptical strain within the blank duringthe forming op eration. This optical strain isnotpf the same-1 character normally thought of; infconnection with stress, but ratheris of aij-charafc "which causes a displacement of the optical; path tain stress without. containing the opticaljstra of sufficient value as to impair the optic erties of the blank .of resinous materi" the blank may'beJpre-formed toga shape" whichf begins to approach the shape of "a, lens or piano between the die halves lfla and "1b.:

After a determined interval of form tion, tier. 1

ing fluid may be circulated through the-die ture of the'blank of resinous material-bold 22 moves the die half Illa into enupon the dies is relatively light to prevent any alterationof the physical shape of the blank whilecold'. However, upon heating the blank to elevate'its temperature to permit forming thereof -=within the dies l5, the pressure applied to the die "be increased. -to;prevent the formed blank .hfrom-attemptingto[return to its normal preformed condition due to the tendency of relief of illteinal stress-upon heating. At this point,

: owever, -it must be observed that the pressure inch seemed to the blank of resinous material N erwhichdetermined to produce a 'te' tion' of lthe blankwhich will not createoptica stra After the pressure-has increased upon the diesls-to a point which balances the tendency of the blank-to return to' normal position, the dies I! will cause a further formation of the blank of resinous material.

As heretofore mentioned, the dies ii are provided with surfaces of optical curvature which.

approximate the surfaces of optical curvature to be produced upon the lens or plane. Thus, the

dies vii'are arranged to produce the greatest mass movement of the blankof resinous material and providethe substantially correct surface of curvature upon the blank! The pressure increase upon the dies -l5 is governed; in accordance with the aforementioned predeterminedj'rate offormation so that when the blank is completely formed with Si e" dies 15; there will be substantially no opticals'trainyalthoug'h, there may be some, stress.

I ,Siuce synthetic resinous materials are all accompanled by the characteristic of plastic flow,

{it can readilybe seen that the second heating of a" formed' blankwill have a tendency to relieve the stress of forming from the previous operation, since the normal tendency of the material willbe to flow'up'on a re-heating as long as there is-sjtres'sfwithin-the-blank of material. While the stress of the previous formingoperation may be 7 substantially relieved during the early portion of the secondoperation, additional stress is'added by the additionalforming operation so that the v blank of resinous'r'nat'erial leaves the second forming operationgwith stress, but substantially no I optical-strain;

dies Iinayfbecooled to permit theblank to die It. However, the

n completion of the forming operation, the

as mlsnw a a s m t:

vplano. The surface which it would tend to return to the normal preformed condition, whereby the blank may be re; moved from the dies. Upon removal of the blank of resinous material from the dies IS, the approximate'curvature of the lens or piano has been imparted thereto. However, as previously stated, the cast dies 15 cannot impart a surface finish to a blank of resinous material of sufliclently high degree to satisfy optical requirements. Hence, the formed blank is then placed within the dies l6. These dies, as previously described, are provided with a highly finished metal surface and are of considerably more accurate curvature than the previous dies IS. The dies is form the blank of Y resinous material to the new form of curvature of the dies i6, and upon heating therein, tend to relieve'the stress of forming of the previous operation. Since the die I 6 is not for the purpose of moving large masses of material, the stress relief within this die is considerably greater than encountered in the dies |5.. At this point of forming, the blank of resinous material has substantially the exact curvature of a lens or finish however, is still insufficient for optical perfection.

The forming operations to this point, have been accomplished in metal dies, since the heattransfer of metal dies is considerably higher than through any other form of material, and can more uniformly apply heat to a blank of resinous material, which uniformity is particularly noticeable for lenses having varying thicknesses of material in various portions thereof.

The blank of resinous material is hereafter placed within dies having surfaces of optical curvature which are faced with glass, or the die itself can be constructed of glass. Normally glass is not a successful medium for forming resinous material, since the material has an aflinity for the glass when any large massof material is moved. The ainnity of the resin for the glass has resulted in internal mass movement in the blank without substantial surface movement causing undesired strain which impaired the optical properties of the material. However, the glass surfaced die does impart an extremely high finish upon a surface of a blank of resinous material if there is substantially no movement of the surfaceof the material within the die. Hence, the glass die is used for the purpose of providing a surface finish upon the blank of resinous material.

Since the blank of resinous material passes through the same cycle of heating, formation and cooling, as described with regard the die l5, and since the glass dies are not for the purpose of making any substantial correction upon the optically curved surfaces of the blank of resinous material, it may be seen that the heating cycle of the last operation will have a tendency to relieve the stress to a greater degree than either of the previous forming operations.

To provide an apparatus for conveniently carrying out the purposes of this invention, and since the rate of pressure application upon the dies in the various stages of formation of the resinous blank is substantially equal, I can provide an arrangement wherein the pressure upon all the moldsis insured of being applied at an equal rate at all times. I have previously described the method of producing a lens or piano with regardto four different steps of operation. It is of course conceivable that any one of the intermediatesteps can be eliminated. It is even conment of the material within metal dies, and polishing or surface finishing the thus formed blank within glass dies or glass surfaced dies.

In the arrangement provide preferably for the use of the cast dies l5, the plated dies l6, and the glass dies H, In this arrangement, the dies l5, J8 and I! have their lower halves a, l6a and Ha positioned upon albase of a press. The upper halves lib, l6b and Nb are suspended from a movable press platen 6| by means of ball and socket joints 6!. The movable press platen 6| is connected to the press plunger 63 by means of a ball and socket joint 64. The dies l5, l8 and I! are arranged uponthe base 60 of the press in a manner that their central vertical axes pass through the apexes of anequilateral triangle. Thus, when the press platen 6| is moved downwardly carrying the upper halves-of the dies into engagement with the lower halves, the pressure applied by the plunger 63 will be evenly distributedbetween the three dies I5, l6 and I1 respectively.

To prevent axial mis-alignment of the upper halves'of the dies, with respect the lower halves thereof, a pair of vertical guide rods 65 is provided for each'of the movable dies I512, I611 and Nb. Y These guide rods extend through ears 66 extending from the respective movable die halves I 5b, i 6b and I lb, whereby the movable die halves are guided in their vertical axial relation with respect the lower or stationary die halves Ilia, Ilia and Na. This arrangement has particular merit with regard to applicant's method of producing lenses in that three blanks of resinous material can be simultaneously formed in different steps of formation, insuring that the pressure of formation and the rate of pressure application upon the resinous lens blank will be identically the same for all of the steps of formation of .the particular lens.

As a modified arrangement for providing even distribution of pressure between other pluralities of die members, I provide a. die carrying platen 10 (see Figure 10) which carries a plurality of stationary die members II. These die members H are provided with threaded extending portions 12 which engage threaded openings 13 in the die carrying platen 10. The dies H may be ad- .iusted vertically to bring them all to substantially the same height, consideration being given the slight varying thickness of the lens which can be formed within the various die members. Set screws 14 are provided to retain the dies H and properly adjust their positions.

While the form and embodiment of the invention has been described with regard to specific apparatus, the invention is not to be limited ex cept as to means and apparatus coming within the purview of the claims. I

Having thus fully described my invention, what I claim as new and desire to secure by Letters Patent, is: 1

1. An' apparatus for simultaneously producing a plurality of forming operations upon a plurality of blanks of resinous material to form ophthalmic articles which includes, a plurality-of 'pairsof cooperating forming dies, means rigidly supporting process may be produced by for producing even distribution of forming pressure upon the various dies 'of a companion set, I

said supporting means,

tive movement therebetween, a single pivot means for suspending each of said opposite halves of each of said forming dies upon said movable means to permit complete freedom of swinging movement of said die half relative to said supporting means, means for moving said movable means, and a single pivot means for suspending said movable means upon the means for moving the same for complete freedom of swinging movement relative thereto whereby said movable means and said dies carried thereby have freedom of movement to cause equal distribution of pressure upon blanks of resinous material that are disposed between said co-operating dies.

2. An apparatus for simultaneously producing a plurality of forming operations upon a plurality of blanks of resinous material to formophthalmic articles which includes, a plurality of pairs of co-operating forming dies, means rigidly supporting one ofthe halves of each pair of forming dies, movable means for supporting the opposite half of each of said forming dies for producing relative movement therebetween, a single pivot means for suspending each of said opposite halves of each of said forming dies upon said movable means to permit complete freedom or swinging movement of saiddie half relative to movable means, a single pivot means for suspending said movable means upon the means for moving the same for complete freedom of swinging movement relative thereto whereby said movable means and said dies carried thereby have freedom of movement to cause equal distribution of pressure upon blanks of resinous material that are disposed between said co-operating dies, and meansdisposed parallel to the axis 01' said co-operating dies for guiding the same in axial alignment with one another.

3. An apparatus for simultaneously producing means for moving said a plurality of forming operations upon a plurality of blanks of resinous material which consists of a plurality of pairs of forming dies, means'rigidly supporting one of thehalves of each pair of forming dies, movable means for supporting the opposite half of each of said forming dies, pivot means consisting of a ball and socket joint for supportng said other half of each of said forming dies upon said movable means, power means, and means consisting of a ball and socket joint for pivotally supporting said movable means upon said power means, whereby said movable means and said diescarried thereby are movable with respect to each other and with respect to said power means to cause equal distribution of pressure from said power means to all of said dies.

4. An apparatus for simultaneously producing a plurality of forming operations upon a plurality of blanks of resinous material which consists of the die faces thereof in proper a plurality of pairs of forming dies, means for adjusting the relative positions of each of said dies with respect to one another for disposing horizontal relationship with respect to one another to accommodate resinous blanks of slightly different thickness, means rigidly supporting one of the halves of each pair of forming dies, movable means for supporting the opposite half of each of said forming dies, flexible means consisting of ball and socket joints for supporting said other half of each of said forming dies upon said movable means, power means, and means consistin of ball and socket joints flexibly supporting said movable means upon said power means, whereby said movable means and said dies carried thereby are movable with respect to each other and with respect to said power means to cause 'equal distribution of pressure from said power means to all of saiddies. CHARLES V. SMITH. 

